Fayat Group BOMAG BW 226 DH-4 User manual

Service - Manual
Catalogue number.
008 916 89 06/2012
BW 226 DH-4
BVC
S/N 101 582 86 1109 >
S/N 101 584 08 ....
Single drum roller

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Table of Contents
BOMAG 3008 916 89
General 9
1.1 Introduction 10
1.2 Safety regulations 11
1.3 General repair instructions 16
1.4 Tightening torques 30
BOMAG single drum rollers 35
2.1 BOMAG single drum rollers 36
Technical data 43
3.1 Technical data 44
Maintenance 49
4.1 General notes on maintenance 50
4.2 Fuels and lubricants 51
4.3 Table of fuels and lubricants 54
4.4 Running-in instructions 56
4.5 Maintenance table 57
E-Plan wiring diagrams 61
5.1 Understanding wiring diagrams 62
5.2 Circuit symbols in the circuit diagram 71
5.3 Identification of switch blocks in the wiring diagram 74
5.4 Designation of components in the wiring diagram 75
5.5 Terminal designations in wiring diagram 76
Electrics 79
6.1 Battery ground and analog ground 80
6.2 Current and voltage 80
6.3 Pulse Width Modulation (PWM) 83
6.4 Resistance 85
6.5 Series / parallel connection 87
6.6 Ohm's law 89
6.7 Electrical energy 89
6.8 Formula diagram 90
6.9 Metrology 91
6.10 Diodes, relays, fuses 95
6.11 Telemecanique switch 98
6.12 Plug connectors 100
6.13 Magnetic coil plug 100
6.14 Deutsch plug, series DT and DTM 102
6.15 Inductive proximity switches 107
6.16 Plugs and terminals in spring clamping technology 109
6.17 Batteries 113
6.18 Battery service 116
6.19 Starting with jump wires 117
6.20 Main battery switch 118
6.21 Overview of electric components 119
6.22 Cabin 130
6.23 Fuses 131
6.24 Main battery fuse 132
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Table of Contents
BOMAG4008 916 89
6.25 Electronic control units 133
6.26 Checking the voltage supply for the control unit 135
6.27 Diagnostics concept 143
Electronic modules 147
7.1 Electrics SX 149
7.2 Electrics MESX 245
7.3 Electric module A108 317
Engine electrics 321
8.1 EMR3 system components 322
8.2 Pin assignment of engine control EDC16 / EMR3 327
8.3 Rotary speed sensor for camshaft 332
8.4 Crankshaft speed sensor 333
8.5 Rail pressure sensor 334
8.6 Fuel pressure sensor 336
8.7 Fuel control unit 337
8.8 Injector 339
8.9 Oil pressure sensor 340
8.10 Sensor for charge air temperature and charge air pressure 342
8.11 EMR coolant temperature sensor 344
8.12 Glow plugs 346
8.13 Sensor, water in fuel 346
8.14 Fuel pre-heating 347
8.15 Rotary switch for engine speed 348
8.16 Data collector 348
8.17 Fault display 352
8.18 Diagnose with SERDIA 353
8.19 Diagnose with CAN-bus 356
8.20 Diagnostics interface 357
8.21 EMR3 List of fault codes 360
8.22 Generator 431
8.23 Replacing the voltage regulator 440
8.24 Electric starter 442
BOMAG, Variocontrol 449
9.1 Variocontrol 450
9.2 Control circuit and MESX 456
9.3 Acceleration transducer 457
9.4 Potentiometer on the slewing motor, B62 458
9.5 Display and control elements
Variocontrol 462
9.6 Description of indicating and control elements
Variocontrol 463
9.7 BVC/BTM05 settings before start-up 464
9.8 Variocontrol, selecting the operating mode 467
9.9 Measuring pass with Variocontrol 469
9.10 Teaching distance pulses 472
9.11 Amplitude limitation (BVC only) 473
Hydraulics 477
10.1 Hydraulic circuit 478
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Table of Contents
BOMAG 5008 916 89
10.2 Travel and vibration pump, H1 480
10.3 Troubleshooting axial piston pumps 487
10.4 Travel motor 51 C/D 110 490
10.5 Vibration motor A2FM80 492
10.6 Axial piston swash plate principle / motor 494
10.7 Trouble shooting, variable displacement axial piston motor 496
10.8 External gear pumps 498
10.9 Slewing motor 500
10.10 Travel circuit 502
10.11 Stopping the machine, operating the parking brake 511
10.12 Towing in case of an engine failure 511
10.13 Adjust the parking brake 513
10.14 Vibration circuit 514
10.15 Check the hydraulic oil level 523
10.16 Changing hydraulic oil and breather filter 523
10.17 Replace hydraulic oil filter 524
Electric steering 527
11.1 Steering circuit 528
11.2 Electric steering wheel 536
Hydraulic steering (optional) 537
12.1 Steering circuit 538
Tests and adjustments 545
13.1 Special tools, tests and adjustments 546
13.2 Activate service mode 550
13.3 Driving against the closed brake 552
13.4 Turn the steering against an end stop. 554
13.5 Check the leakage rate of the vibration motor 556
13.6 Pressure test in steering circuit 557
Flushing and bleeding 559
14.1 Special tools for flushing 560
14.2 Flushing - general 565
14.3 Flushing schematic travel circuit (distribution travel pump) 567
14.4 Flushing the travel circuit (travel pump distribution) 569
14.5 Flushing schematic travel circuit (distribution axle motor) 575
14.6 Flushing the travel circuit (axle motor distribution) 577
14.7 Flushing schematic for vibration drive 582
14.8 Flushing the vibration circuit 583
14.9 Bleeding the travel circuit 587
14.10 Bleeding the vibration circuit 589
582 502 15 dust protection / 582 502 16 gasket 591
15.1 Assembling the dust protection 592
Engine 597
16.1 Diesel engine 598
16.2 Engine description TCD 2012 599
16.3 Lubrication oil circuit TCD 2012 / 2013 601
16.4 Coolant circuit TCD 2012 / 2013 602
16.5 Fuel system TCD 2012 / 2013 603
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Table of Contents
BOMAG6008 916 89
16.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 607
16.7 Exhaust gas recirculation TCD 2012 / 2013 613
16.8 Wastegate - charge pressure controller on TCD-engines 614
16.9 Engine problems 616
16.10 Check the engine oil level 619
16.11 Change engine oil and oil filter cartridge 619
16.12 Change the fuel pre-filter cartridge 620
16.13 Replace the fuel filter cartridge 622
16.14 Check, clean the water separator 623
16.15 Check the coolant level 623
16.16 Change the coolant 624
16.17 Checking the thermostat in disassembled state 625
16.18 Service the combustion air filter 626
16.19 Check the dust separator 628
16.20 Cleaning the oil bath air filter 629
16.21 Adjust the valve clearance 629
16.22 Checking / replacing the ribbed V-belt 630
16.23 Check the engine mounts 631
16.24 Replacing the crank case pressure ventilation valve 632
16.25 Engine conservation 632
16.26 Special tools, Deutz engine (TCD 2012 2V) 633
Air conditioning system 649
17.1 Physical basics 650
17.2 Refrigerant R134a 653
17.3 Compressor oil / refrigeration oil 654
17.4 Working principle of the air conditioning system 655
17.5 Monitoring devices 655
17.6 Description of components 656
17.7 Measuring the compressor oil level 662
17.8 Checking the magnetic clutch 662
17.9 Inspection and maintenance work 663
17.10 Checking, replacing the refrigerant compressor V-belt 664
17.11 Service the air conditioning 665
17.12 Drying and evacuation 667
17.13 Emptying in case of repair 668
17.14 Leak test 668
17.15 Filling instructions 669
17.16 Trouble shooting in refrigerant circuit, basic principles 672
17.17 Trouble shooting, refrigerant circuit diagram 676
17.18 Trouble shooting procedure 677
17.19 Steam table for R134a 687
Cabin assembly 693
18.1 Preparations 695
18.2 Cabin assembly 696
18.3 Final function tests and checks 701
Replacing the cab window panes 703
19.1 Assembly of window panes 704
19.2 Special tools, cabin windows 705
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Table of Contents
BOMAG 7008 916 89
19.3 Auxiliary materials 706
19.4 Removing and installing the window pane 708
Drum 713
20.1 Repair overview for drum 714
20.2 Removing and installing the drum 724
20.3 Dismantling the drum 732
20.4 Assembling the vibrator unit 736
20.5 Installing the exciter unit 777
20.6 Changing the rubber buffers and adjusting the pretension 784
20.7 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol 787
Oscillating articulated joint 793
21.1 Special tools 794
21.2 Repair overview oscillating articulated joint 796
21.3 Removing and installing the oscillating articulated joint 800
21.4 Dismantling the oscillating articulated joint 802
21.5 Assembling the oscillating articulated joint 805
Suppliers documentation 809
22.1 Travel and vibration pump 811
22.2 Vibration motor 925
22.3 Axle drive motor 955
22.4 Steering valve 1049
22.5 Axle 1083
Circuit diagrams 1173
23.1 Hydraulic diagram 63 1175
23.2 Wiring diagram 12 1187
23.3 Wiring diagram 88 1253
23.4 Wiring diagram 132 1321
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Table of Contents
BOMAG8008 916 89
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BOMAG 9008 916 89
1 General
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1.1 Introduction
BOMAG10 008 916 89
1.1 Introduction
This manual addresses the professionally qualified
personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.
Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information
Use only genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
!Danger
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
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